Positive completion coupler insert and coupler

ABSTRACT

A positive completion coupler insert ( 100 ) configured to be inserted into a coupler ( 150 ) is provided according to the invention. The coupler insert ( 100 ) includes a conduit support insert ( 110 ) configured to be retained in a coupler bore ( 151 ) of the coupler ( 150 ) and a conduit support ( 140 ) configured to fit into and be retained by the conduit support insert ( 110 ). The conduit support ( 140 ) is configured to generate a first audible sound when inserted to a first insertion point in the conduit support insert ( 110 ) and is configured to generate a second audible sound when inserted to a second insertion point.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a positive completion coupler insertand coupler.

2. Statement of the Problem

Many large vehicles employ pneumatic systems for some onboard componentsor systems. For example, trucks typically include air brakes connectedto an air system. The air brakes can include multiple axles or caninclude tractor and trailer brake systems. A system of hoses connectsvarious components of the air system.

Assembly of a vehicle air system may include connecting hoses tocouplers. Assembly of air systems for vehicles is one area in whichhoses or lines may be required to be connected in the factory.Typically, an assembly worker pushes a hose into a correspondingcoupler. This assembly is complete when the hose comes into contact withan inside end of the coupler. Therefore, in the prior art, proper andcomplete assembly relies on the assembly worker's experience andattentiveness in performing the insertion of the hose.

Improper assembly of hoses to corresponding couplers can lead toinspection failures or customer complaints. Failure of a couplerconnection in an air brake system can result in sudden and unexpecteddeployment of the vehicle's brakes. Therefore, it is very important thatthe assembly process be efficient and highly failure-proof.

SUMMARY OF THE INVENTION

A positive completion coupler insert configured to be inserted into acoupler is provided according to an embodiment of the invention. Thecoupler insert comprises a conduit support insert configured to beretained in a coupler bore of the coupler and a conduit supportconfigured to fit into and be retained by the conduit support insert.The conduit support is configured to generate a first audible sound wheninserted to a first insertion point in the conduit support insert and isconfigured to generate a second audible sound when inserted to a secondinsertion point.

A positive completion coupler for a conduit is provided according to anembodiment of the invention. The coupler comprises a coupler bore, aconduit support insert configured to be retained in the coupler bore,and a conduit support configured to fit into and be retained by theconduit support insert. The conduit support is configured to generate afirst audible sound when inserted to a first insertion point in theconduit support insert and is configured to generate a second audiblesound when inserted to a second insertion point.

A method of assembling a conduit to a positive completion coupler isprovided according to an embodiment of the invention. The methodcomprises inserting a conduit support into a conduit support insert to afirst insertion point with regard to the conduit support insert. A firstaudible sound is generated at the first insertion point by the conduitsupport insert and the conduit support. The method further comprisesinserting the conduit support insert into a coupler bore of the coupler.The method further comprises inserting a conduit into the coupler andmoving the conduit support to a second insertion point with regard tothe conduit support insert. A second audible sound is generated at thesecond insertion point by the conduit support insert and the conduitsupport.

ASPECTS OF THE INVENTION

In one embodiment of the coupler insert, the conduit support comprises asupport portion adapted to receive a conduit and a head portion joinedto the support portion, with the head portion including a first ring anda second ring extending outwardly from the head portion, with the firstring being spaced apart from the second ring.

In yet another embodiment of the coupler insert, the plurality of firstprojections pass over the first ring to reach a first insertion pointduring assembly of the conduit support to the conduit support insert.

In yet another embodiment of the coupler insert, the plurality of secondprojections pass over the first ring to reach a second insertion pointduring assembly of the conduit to the conduit support insert and theconduit support.

In yet another embodiment of the coupler insert, the plurality of firstprojections comprises three first projections.

In yet another embodiment of the coupler insert, the plurality of secondprojections comprises three second projections.

In one embodiment of the coupler, the conduit support insert comprises abody, a first aperture formed in the body, a second aperture formed inthe body and connecting with the first aperture, one or more firstprojections formed in the first aperture and projecting inward into thefirst aperture, and one or more second projections formed in the secondaperture and projecting inward into the second aperture.

In another embodiment of the coupler, the conduit support comprises asupport portion adapted to receive a conduit and a head portion joinedto the support portion, with the head portion including a first ring anda second ring extending outwardly from the head portion, with the firstring being spaced apart from the second ring.

In yet another embodiment of the coupler, the plurality of firstprojections pass over the first ring to reach a first insertion pointduring assembly of the conduit support to the conduit support insert.

In yet another embodiment of the coupler, the plurality of secondprojections pass over the first ring to reach a second insertion pointduring assembly of the conduit to the conduit support insert and theconduit support.

In yet another embodiment of the coupler, the plurality of firstprojections comprises three first projections.

In yet another embodiment of the coupler, the plurality of secondprojections comprises three second projections.

In one embodiment of the method, the conduit support insert comprises abody, a first aperture formed in the body, a second aperture formed inthe body and connecting with the first aperture, one or more firstprojections formed in the first aperture and projecting inward into thefirst aperture, and one or more second projections formed in the secondaperture and projecting inward into the second aperture.

In another embodiment of the method, the conduit support comprises asupport portion that receives the conduit and a head portion joined tothe support portion, with the head portion including a first ring and asecond ring extending outwardly from the head portion, with the firstring being spaced apart from the second ring.

In yet another embodiment of the method, the plurality of firstprojections pass over the first ring to reach the first insertion pointduring assembly of the conduit support to the conduit support insert.

In yet another embodiment of the method, the plurality of secondprojections pass over the first ring to reach the second insertion pointduring assembly of the conduit to the conduit support insert and theconduit support.

In yet another embodiment of the method, the plurality of firstprojections comprises three first projections.

In yet another embodiment of the method, the plurality of secondprojections comprises three second projections.

DESCRIPTION OF THE DRAWINGS

The same reference number represents the same element on all drawings.It should be understood that the drawings are not necessarily to scale.

FIG. 1 shows a conduit support insert according to an embodiment of theinvention.

FIG. 2 is a cross-section of the conduit support insert according to anembodiment of the invention.

FIG. 3 shows the conduit support according to an embodiment of theinvention.

FIG. 4 shows the conduit support assembled to the conduit support insertaccording to an embodiment of the invention.

FIG. 5 shows the conduit support and the conduit support insertassembled to a coupler according to an embodiment of the invention.

FIG. 6 shows the coupler after the conduit support insert and theconduit support have been inserted to the second insertion point by theinsertion of the conduit.

DETAILED DESCRIPTION OF THE INVENTION

FIGS. 1-6 and the following description depict specific examples toteach those skilled in the art how to make and use the best mode of theinvention. For the purpose of teaching inventive principles, someconventional aspects have been simplified or omitted. Those skilled inthe art will appreciate variations from these examples that fall withinthe scope of the invention. Those skilled in the art will appreciatethat the features described below can be combined in various ways toform multiple variations of the invention. As a result, the invention isnot limited to the specific examples described below, but only by theclaims and their equivalents.

FIG. 1 shows a conduit support insert 110 according to an embodiment ofthe invention. Components in common with other figures share referencenumbers. The conduit support insert 110 is configured to be assembled toa conduit support 140 (see FIGS. 3-4) and the two components are furtherassembled to a coupler 150 (see FIGS. 5-6).

FIG. 2 is a cross-section of the conduit support insert 110 according toan embodiment of the invention. The conduit support insert 110 includesa body 111, a first aperture 112, and a second aperture 113. The secondaperture 113 connects with the first aperture 112. In one embodiment,the second aperture 113 is smaller than the first aperture 112. Inanother embodiment, a shoulder 117 is formed within the first apeturebetween an end of the first aperature 112 and one or more firstprojections 115.

In one embodiment, the body 111 is substantially cylindrical and thefirst and second apertures 112 and 113 are substantially cylindrical.However, other shapes are contemplated and are within the scope of thedescription and claims.

The first aperture 112 includes a plurality of first projections 115projecting inward into the first aperture 112. In the embodiment shown,three first projections 115 are included in the conduit support insert110. However, it should be understood that other numbers of firstprojections 115 are contemplated and are within the scope of thedescription and claims.

The second aperture 113 includes a plurality of second projections 116projecting inward into the second aperture 113. In the embodiment shown,three second projections 116 are included in the conduit support insert110. In the embodiment shown, the number of second projections 116matches the number of first projections 115. However, it should beunderstood that other numbers of second projections 116 are contemplatedand are within the scope of the description and claims.

The first and second projections 115 and 116 are used to affix orremovably affix a conduit support 140 to the conduit support insert 110during assembly. The first and second projections 115 and 116 thereforedefine first and second insertion points (see FIGS. 5-6). The firstinsertion point is reached when the conduit insert 140 is partiallyassembled to the conduit support insert 110. A second insertion point isreached when a conduit 190 is assembled to the coupler 150.

It can be seen that a first projection 115 can include a substantiallysloped face 120 and a substantially perpendicular face 121. The slopedface 120 is contacted by a first ring 147 of the conduit support 140when the conduit support 140 is being inserted into the conduit supportinsert 110 to the first insertion point. The sloped face 120 providesease of insertion and provides a substantially self-aligning feature tothe assembly of the two components. The first ring 147 snaps over andengages the perpendicular face 121 of the first projection 115 when theconduit support 140 has been inserted to the first insertion point. As aresult, a first snap or click sound is generated, indicating theengagement of the first ring 147 with the perpendicular face 121.However, other projection shapes are contemplated and are within thescope of the description and claims.

A second projection 116 can include a substantially sloped face 120′ anda substantially perpendicular face 121′. The sloped face 120′ iscontacted by the first ring 147 of the conduit support 140 (see FIG. 3)when the conduit support 140 is being inserted into the conduit supportinsert 110 to the second insertion point. The first ring 147 snaps overand engages the perpendicular face 121′ of the plurality of secondprojections 116 when the conduit support 140 has been inserted to thesecond insertion point. As a result, a second snap or click sound isgenerated, indicating the engagement of the first ring 147 with theperpendicular face 121′. However, other projection shapes arecontemplated and are within the scope of the description and claims.

The second insertion point is achieved during assembly of a conduit 190to the coupler 150 (see FIG. 6), wherein the conduit support insert 110and the conduit support 140 may already be assembled to the coupler 150.No rotation or other manipulation is required.

The first projections 115 are spaced apart from the second projections116 by a predetermined separation distance D1. The predeterminedseparation distance D1 is substantially equal to or larger than the sizeof the first ring 147.

The first and second projections 115 and 116 create a predetermined spanD2. The predetermined span D2 is substantially equal to or less than aspan D3 of the conduit support 140 (see FIG. 3).

The pluralities of projections 115 and 116 are of a predeterminedheight. The height must create enough energy to generate a relativelyloud (i.e., audible) snap or click sounds during assembly. The pluralityof first projections 115 in one embodiment is substantially the sameheight as the plurality of second projections 116. Alternatively, thetwo sets of projections 115 and 116 can be of different heights.

The pluralities of projections 115 and 116 can comprise any shape. Thepluralities of projections 115 and 116 can include rounded projections(i.e., lobes) or can comprise substantially planar faces. The faces canmeet at any desired angle.

Projections are used in the invention instead of a continuous ridge.Because the invention was developed to provide audible sounds when theconduit support 140 is assembled to the conduit support insert 111 andwhen a conduit is fully installed to a coupler, a new and unique couplermechanism has been developed. The coupler mechanism has to provide asatisfactory sound level, provide a positive and reliable couplingaction, and provide the coupling action without requiring excessive orundue force. A circular ridge requires too much force for insertion ofthe conduit support 140 in order to generate a desired sound level.Alternatively, if the height of the circular ridge is reduced in orderto reduce the insertion force, then the energy created by the ridgeduring insertion will not create a satisfactory sound level.

The plurality of second projections 116 can be offset from the pluralityof first projections 115. The offsetting can aid in the manufacturing ofthe conduit support insert 110. However, the offset does not affect theinsertion process, and no rotation is required during the insertion ofthe conduit support 140 into the conduit support insert 110.

The conduit support insert 110 can additionally include a chamfer 118.The chamfer 118 can aid in the alignment and insertion of the conduitsupport insert 110 into the coupler 150. The conduit support insert 110can further include a second aperture flare 114 that eases the insertionof the conduit 190 into the coupler 150.

The conduit support insert 110 can further include one or moreprojections 119. The one or more projections 119 can offer grip surfacesand can further provide a predetermined insertion force when the conduitsupport insert 110 is inserted into the coupler 150. Moreover, theprojections 119 can be of a size to ensure that the conduit supportinsert 110 fits snugly into the bore 151 of the coupler 150.

FIG. 3 shows the conduit support 140 according to an embodiment of theinvention. The conduit support 140 includes a substantially cylindricalsupport portion 142 and a head portion 144 that engages the conduitsupport insert 110. The conduit support 140 further includes a bore 143that extends through both the support portion 142 and the head portion144. The head portion 144 further includes the first ring 147 and thesecond ring 148. The first ring 147 is spaced apart from the second ring148 and is separated from the second ring 148 by a span D3. The firstring 147 is configured to pass over and subsequently engage theplurality of first and second projections 115 and 116 of the conduitsupport insert 110.

In the embodiment shown, the first ring 147 includes a chamfer 149. Thechamfer 149 eases passage of the first ring 147 past both projections115 and 116. In the embodiment shown, the second ring 148 issubstantially rectangular in cross-sectional shape. It should beunderstood that other shapes can be used for the first and second rings147 and 148.

It should be understood that alternatively the first ring 147 cancomprise a plurality of projections, while the plurality of first andsecond projections 115 and 116 can comprise uninterrupted rings.

FIG. 4 shows the conduit support 140 assembled to the conduit supportinsert 110 according to an embodiment of the invention. The conduitsupport 140 has been partially inserted into the conduit support insert110 to the first insertion point. Here, the first ring 147 has passedover the plurality of first projections 115, but has not passed over theplurality of second projections 116 (see also FIG. 5 and the discussionbelow). The two components can now be assembled to the coupler 150.Alternatively, the conduit support insert 110 can be assembled to thecoupler 150 and then the conduit support 140 can be assembled to theconduit support insert 110.

FIG. 5 shows the conduit support 140 and the conduit support insert 110assembled to the coupler 150 according to an embodiment of theinvention. The coupler 150 includes a coupler bore 151. The conduitsupport 140 and the conduit support insert 110 are inserted into thecoupler bore 151. In this figure, the conduit support 140 and theconduit support insert 110 have been assembled to the first insertionpoint. The first ring 147 has passed over the plurality of firstprojections 115, but has not passed over the plurality of secondprojections 116.

The conduit support insert 110 can be retained in the coupler bore 151by other coupler components. For example, in the embodiment shown thecoupler 150 further includes a seal 154, a washer (or spacer) 155, acollet retainer 156, and a collet 157. The collet 157 is held in thecoupler bore 151 by the collet retainer 156 in this embodiment. Thecollet retainer 156 can include one or more projections or ridges thatengage by means of interference in the coupler bore 151. The coupler 150can further include a dust cap 160 that keeps dust and dirt out of theend of the coupler 150. The conduit 190 can pass through a dust capaperture 161 in the dust cap 160.

FIG. 6 shows the coupler 150 after the conduit support insert 110 andthe conduit support 140 have been moved to the second insertion point bythe insertion of the conduit 190. At this point in the assembly process,the first ring 147 has already passed over the plurality of firstprojections 115. Subsequently, in this figure the inserted conduit 190pushes the conduit support 140 far enough into the conduit supportinsert 110 that the first ring 147 now passes over the plurality ofsecond projections 116, as shown in the figure. The first ring 147deforms during this process. In addition, the one or more secondprojections 116 can also deform somewhat during this process.Afterwards, the first ring 147 quickly returns to an originalconfiguration, accompanied by a snapping or clicking sound. The secondring 148 acts as an insertion depth limit, wherein the second ring 148hits the shoulder 117 and stops the conduit support 140 from movingfurther into the conduit support insert 110.

An alternate configuration of the seal 154 is shown. The seal 154 canplace a retaining force on the conduit 190, along with ridges or othermechanisms of the collet 157.

Advantageously, the conduit support insert 110 and the conduit support140 can provide an audible signal when the first insertion point hasbeen achieved. Likewise, the conduit support insert 110 and the conduitsupport 140 can provide an audible signal when the second insertionpoint has been achieved. This ensures that assembly of the conduit 190to the coupler is satisfactorily performed. Full insertion of theconduit 190 leads to more efficient assembly and fewer quality issues.

What is claimed is:
 1. A positive completion coupler insert (100)configured to be inserted into a coupler (150), the coupler insert (100)comprising: a conduit support insert (110) configured to be retained ina coupler bore (151) of the coupler (150), with the conduit supportinsert (110) being a one-piece body comprising: a first aperture (112)formed in a body (111) and a second aperture (113) formed in the body(111) and connecting with the first aperture (112), with a shoulder(117) formed within the first aperture (112); one or more firstprojections (115) formed in the first aperture (112) and projectinginward into the first aperture (112), with the one or more firstprojections (115) being non-continuous around a common interior surfacecircumference of the first aperture (112) and the shoulder (117) beinglocated between an end of the first aperture (112) and the one or morefirst projections (115); and one or more second projections (116) formedin the second aperture (113) and projecting inward into the secondaperture (113), with the one or more second projections (116) beingnon-continuous around a common interior surface circumference of thesecond aperture (113), wherein the first aperture (112) has a firstdiameter and the second aperture (113) has a second diameter, the firstdiameter being different from the second diameter; and a conduit support(140) configured to fit into and be retained by the conduit supportinsert (110), with the conduit support (140) comprising: a supportportion (142) adapted to receive a conduit (190); and a head portion(144) joined to the support portion (142), with the head portion (144)including a first ring (147) and a second ring (148) extending outwardlyfrom the head portion (144), with the first ring (147) being spacedapart from the second ring (148); wherein the first ring (147) passesover and resiliently snaps over the one or more first projections (115)to reach a first insertion point during assembly of the conduit support(140) to the conduit support insert (110) and wherein the conduitsupport (140) is configured to generate a first audible sound wheninserted to the first insertion point in the conduit support insert(110); wherein the first ring (147) passes over and resiliently snapsover the one or more second projections (116) to reach a secondinsertion point during assembly of the conduit (190) to the conduitsupport insert (110) and the conduit support (140) and wherein theconduit support (140) is configured to generate a second audible soundwhen inserted to the second insertion point; and wherein the second ring(148) rests against the shoulder (117 when the first ring (147) is atthe second insertion point.
 2. The coupler insert (100) of claim 1, withthe one or more first projections (115) comprising three firstprojections (115).
 3. The coupler insert (100) of claim 1, with the oneor more second projections (116) comprising three second projections(116).
 4. A positive completion coupler (150) for a conduit (190), thecoupler (150) comprising: a coupler bore (151); a conduit support insert(110) configured to be retained in the coupler bore (151), with theconduit support insert (110) being a one-piece body comprising: a firstaperture (112) formed in a body (111) and a second aperture (113) formedin the body (111) and connecting with the first aperture (112), with ashoulder (117) formed within the first aperture (112); one or more firstprojections (115) formed in the first aperture (112) and projectinginward into the first aperture (112), with the one or more firstprojections (115) being non-continuous around a common interior surfacecircumference of the first aperture (112) and the shoulder (117) beinglocated between an end of the first aperture (112) and the one or morefirst projections (115); and one or more second projections (116) formedin the second aperture (113) and projecting inward into the secondaperture (113), with the one or more second projections (116) beingnon-continuous around a common interior surface circumference of thesecond aperture (113), wherein the first aperture (112) has a firstdiameter and the second aperture (113) has a second diameter, the firstdiameter being different from the second diameter; and a conduit support(140) configured to fit into and be retained by the conduit supportinsert (110), with the conduit support (140) comprising: a supportportion (142) adapted to receive a conduit (190); and a head portion(144) joined to the support portion (142), with the head portion (144)including a first ring (147) and a second ring (148) extending outwardlyfrom the head portion (144), with the first ring (147) being spacedapart from the second ring (148); wherein the first ring (147) passesover and resiliently snaps over the one or more first projections (115)to reach a first insertion point during assembly of the conduit support(140) to the conduit support insert (110) and wherein the conduitsupport (140) is configured to generate a first audible sound wheninserted to the first insertion point in the conduit support insert(110); wherein the first ring (147) passes over and resiliently snapsover the one or more second projections (116) to reach a secondinsertion point during assembly of the conduit (190) to the conduitsupport insert (110) and the conduit support (140) and wherein theconduit support (140) is configured to generate a second audible soundwhen inserted to the second insertion point; and wherein the second ring(148) rests against the shoulder (117 when the first ring (147) is atthe second insertion point.
 5. The coupler (150) of claim 4, with theone or more first projections (115) comprising three first projections(115).
 6. The coupler (150) of claim 4, with the one or more secondprojections (116) comprising three second projections (116).